Method and apparatus for holding parts during manufacturing processing

ABSTRACT

A method for processing parts. In one advantageous embodiment, a setoff set of studs are welded to a part to form a set of fixed studs. A set of tabs are attached to the set of fixed studs. The set of tabs are affixed to a manufacturing tool.

BACKGROUND INFORMATION

1. Field

The present disclosure relates generally to manufacturing parts and inparticular to a method and apparatus for holding parts duringmanufacturing processing.

2. Background

Manufacturing involves the use of tools and labor to produce or makethings for use or sale. With this type of process, raw materials aretransformed into finished goods or products, typically on a large scale.With the manufacturing of an aircraft, metal working combined with otheroperations, such as fatigue enhancement, chemical processing, andapplication of paint are often performed to create finished structuresor machine parts. This metal working may include processes, such asmilling, turning, cutting, drilling, and threading.

With these processes, it is common to hold a part in place while aparticular process is being performed. For example, in creating a part,such as an air foil or frame for an aircraft, a block of raw materialmay be machined to form the component. This block of raw material istypically made of a metal, such as titanium, steel, or aluminum. Thisblock of material is typically larger than the component being made. Forexample, in manufacturing a frame for a fuselage, a portion of the framemay be machined or cut out of a rectangular piece of titanium. Thetypical “buy to fly” ratio may be thirty to one in which twenty-ninepounds of material is machined into chips to create one pound of a partthat is used on an aircraft.

For example, the size or amount of material needed for a particular parttakes into account a need for sufficient material to machine or cut outsections that may be used to hold the part during manufacturing. Takinginto account a need for sections that may be used to hold the part, theamount of material used to create the part increases. The amount ofmaterial needed includes more than just the sections for holding thepart during manufacturing. The block of material also is large enough toallow for these components to be machined or created during themachining process.

SUMMARY

The different advantageous embodiments provide a method for processingparts. In one advantageous embodiment, a setoff set of studs are weldedto a part to form a set of fixed studs. A set of tabs are attached tothe set of fixed studs. The set of tabs are affixed to a manufacturingtool.

In another advantageous embodiment, a manufacturing system comprises aplurality of studs, a welding unit, a plurality of tabs, and amanufacturing tool. The welding unit is capable of rigidly attaching theplurality of studs to a part. The plurality of tabs is capable of beingattached to studs in the plurality of studs. Each tab in the pluralityof tabs has a channel to receive a portion of a stud and mechanicallyattach the stud to the tab. The manufacturing tool is capable of holdingthe part in place for processing using the plurality of tabs attached tothe plurality of studs.

The features, functions, and advantages can be achieved independently invarious embodiments of the present invention or may be combined in yetother embodiments in which further details can be seen with reference tothe following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are setforth in the appended claims. The invention itself, however, as well asa preferred mode of use, further objectives and advantages thereof, willbest be understood by reference to the following detailed description ofan advantageous embodiment of the present invention when read inconjunction with the accompanying drawings, wherein:

FIG. 1 is a diagram illustrating an aircraft manufacturing and servicemethod in accordance with an advantageous embodiment;

FIG. 2 is a diagram of an aircraft in which an advantageous embodimentmay be implemented;

FIG. 3 is a block diagram illustrating components used to manufacture apart in accordance with an advantageous embodiment;

FIG. 4 is a diagram illustrating parts on which tabs may be implementedin accordance with an advantageous embodiment;

FIG. 5 is a diagram illustrating a frame with tabs in accordance with anadvantageous embodiment;

FIG. 6 is a diagram illustrating the welding of studs onto a part with awelding unit in accordance with an advantageous embodiment;

FIG. 7 is a diagram illustrating the welding of a stud onto a part inaccordance with an advantageous embodiment;

FIG. 8 is a cross-sectional view of a stud attached to a part inaccordance with an advantageous embodiment;

FIG. 9 is a more detailed cross-sectional view of an interface between astud and a part in accordance with an advantageous embodiment;

FIG. 10 is a diagram illustrating the placement of a tab onto a part inaccordance with an advantageous embodiment;

FIG. 11 is a diagram illustrating the holding of a part on amanufacturing tool in accordance with an advantageous embodiment;

FIG. 12 is a diagram illustrating a cross-section of a tab in a stud inaccordance with an advantageous embodiment;

FIG. 13 is a front view of a tab in accordance with an advantageousembodiment; and

FIG. 14 is a flowchart of a process for manufacturing a part inaccordance with an advantageous embodiment.

DETAILED DESCRIPTION

Referring more particularly to the drawings, embodiments of thedisclosure may be described in the context of aircraft manufacturing andservice method 100 as shown in FIG. 1 and aircraft 200 as shown in FIG.2. Turning first to FIG. 1, a diagram illustrating an aircraftmanufacturing and service method is depicted in accordance with anadvantageous embodiment. During pre-production, exemplary aircraftmanufacturing and service method 100 may include specification anddesign 102 of aircraft 200 in FIG. 2 and material procurement 104.During production, component and subassembly manufacturing 106 andsystem integration 108 of aircraft 200 in FIG. 2 takes place.Thereafter, aircraft 200 in FIG. 2 may go through certification anddelivery 110 in order to be placed in service 112. While in service by acustomer, aircraft 200 in FIG. 2 is scheduled for routine maintenanceand service 114, which may include modification, reconfiguration,refurbishment, and other maintenance or service.

Each of the processes of aircraft manufacturing and service method 100may be performed or carried out by a system integrator, a third party,and/or an operator. In these examples, the operator may be a customer.For the purposes of this description, a system integrator may include,without limitation, any number of aircraft manufacturers andmajor-system subcontractors; a third party may include, withoutlimitation, any number of venders, subcontractors, and suppliers; and anoperator may be an airline, leasing company, military entity, serviceorganization, and so on.

With reference now to FIG. 2, a diagram of an aircraft is depicted inwhich an advantageous embodiment may be implemented. In this example,aircraft 200 is produced by aircraft manufacturing and service method100 in FIG. 1 and may include airframe 202 with a plurality of systems204 and interior 206. Examples of systems 204 include one or more ofpropulsion system 208, electrical system 210, hydraulic system 212, andenvironmental system 214. Any number of other systems may be included.Although an aerospace example is shown, different advantageousembodiments may be applied to other industries, such as the automotiveindustry.

Apparatus and methods embodied herein may be employed during any one ormore of the stages of aircraft manufacturing and service method 100 inFIG. 1. For example, components or subassemblies produced in componentand subassembly manufacturing 106 in FIG. 1 may be fabricated ormanufactured in a manner similar to components or subassemblies producedwhile aircraft 200 is in service 112 in FIG. 1.

Also, one or more apparatus embodiments, method embodiments, or acombination thereof may be utilized during production stages, such ascomponent and subassembly manufacturing 106 and system integration 108in FIG. 1, for example, by substantially expediting the assembly of orreducing the cost of aircraft 200. Similarly, one or more of apparatusembodiments, method embodiments, or a combination thereof may beutilized while aircraft 200 is in service 112, for example and withoutlimitation, to maintenance and service 114 in FIG. 1.

The different embodiments provide a method and apparatus for processinga part. In one advantageous embodiment, a set of studs are welded to apart to form a set of fixed studs. A set of tabs are attached to the setof fixed studs. The set of tabs are affixed to a manufacturing tool.This type of tab allows for less materials to be used in initiallyforming the part because additional material is not required to producetabs on the part.

With reference next to FIG. 3, a block diagram illustrating componentsused to manufacture a part is depicted in accordance with anadvantageous embodiment. In this example, manufacturing system 300includes controller 302, welding unit 304, placement unit 306,manufacturing tool 308, and holding system parts 310. Studs 312 and tabs314 are obtained from holding system parts 310. These differentcomponents are used to perform manufacturing processes on part 316.

Welding unit 304 may obtain studs 312 from holding system parts 310 andweld studs to part 316. Placement unit 306 obtains tabs 314 and attachesthose tabs to studs 312. The combination of studs 312 and tabs 314 forma holding component used to hold part 316 when processing part 316 withmanufacturing tool 308. Controller 302 controls welding unit 304,placement unit 306, and manufacturing tool 308. Controller 302 controlsthe application or welding of studs 312 by welding unit 304 to part 316.Further, controller 302 controls the attachment of tabs 314 by placementunit 306 to studs 312. Also, controller 302 may control the processingof part 316 by manufacturing tool 308.

In these examples, the different components are illustrated asfunctional components and may be implemented using a variety ofdifferent systems or personnel. For example, controller 302 may be acomputer and/or human operator. Welding unit 304 may be a hand heldwelding unit. In other examples, welding unit 304 may be a roboticwelding unit that automatically receives or feeds studs from holdingsystem parts 310 into the welding unit for welding studs 312 to part316. Placement unit 306 may be, for example, the same human operator ascontroller 302. In other embodiments, placement 306 may be a roboticsystem that obtains tabs 314 from holding system parts 310 and attachestabs 314 to studs 312 on part 316.

Manufacturing tool 308 may take a variety of forms. For example,manufacturing tool 308 may be a computer, a robotic manufacturing tool,or a manufacturing tool operated by a human operator. Manufacturing tool308 may be, for example, without limitation, a milling machine, a lathe,a cutting machine, a drilling and threading machine, a grinding machine,a welding machine, or a paint system.

Turning now to FIG. 4, a diagram illustrating parts on which tabs may beimplemented is depicted in accordance with an advantageous embodiment.In this example, structure 400 is a portion of a fuselage. Structure 400includes side frames, such as frames 402, 404, 406, 408, 410, 412, 414,416, 418, 420, 422, 424, and 426. These different parts may bemanufactured within manufacturing system 300 in FIG. 3 using tabs.

With reference now to FIG. 5, a diagram illustrating a frame with tabsis depicted in accordance with an advantageous embodiment. In thisexample, frame 500 has tabs 502, 504, 506, 508, 510, 512, 514, 516, 518,520, 522, and 524 attached on surface 526 and surface 528. These tabsare used to attach frame 500 to a manufacturing tool for processing. Inthese examples, the tabs are indirectly attached to surface 526 andsurface 528. The tabs are mechanically attached or locked to studs thatare not visible in this illustration. These studs are rigidly fixed tothese surfaces.

With reference now to FIG. 6, a diagram illustrating the welding ofstuds onto a part with a welding unit is depicted in accordance with anadvantageous embodiment. In this example, stud gun 600 and welder 602form welding unit 604, which is an example of welding unit 304 in FIG.3. As depicted, welding unit 604 is a capacitor discharge stud weldingunit. This type of welding unit performs capacitive welding and may beportable. Welding unit 604 is able to weld dissimilar materials to eachother. Further, this type of welding is two times as fast as contactwelding.

With a welding unit, such as welding unit 604, the portability providesfor an ability to perform the welding of studs off line or away from anexpensive machining center. This type of portability and flexibilityallows for the attachment of studs to parts at different points orplaces. Further, capacitor discharge welding reduces the heat affectedzone to a minimal amount. Thus, this type of welding ensures that all ofthe heat affected zone will be removed during the subsequent machiningprocess. This removal of heat affected zones is performed to maintainpart integrity on critical components.

Additionally, unlike friction welding, high contact forces are notneeded with this type of welding. Of course, other types of welding,such as, for example, contact welding, friction welding, solid statewelding, fusion welding, and diffusion welding also may be used,depending on the particular implementation.

In this particular example, part 606 is grounded in stud gun 600 andwelds a stud onto part 606. Of course, other types of attachmentprocesses other than welding may be used to attach a stud onto partother than welding. For example, without limitation, a stud could beadhesively attached to part 606.

Turning next to FIG. 7, a diagram illustrating the welding of a studonto a part is depicted in accordance with an advantageous embodiment.In this example, stud 700 is ready to be welded onto part 708. In thisexample, studs 700, 702, and 704 are shown in different phases of beingwelded to surface 706 of part 708. In this example, tip 710 is incontact with surface 706 of part 708. Stud 702 illustrates a stud inwhich welding has begun. As can be seen, the material around tip 712 hasbegun to reflow. The welding causes the material at and around tip 712to melt or reflow and coalesce with surface 706. Stud 704 illustrates astud in which welding has been completed.

In these examples, the welding may take around 0.004 seconds tocomplete. Further the welding may be performed using a number ofdifferent types of energy sources. For example, a gas flame, an electricarc, a laser, an electron beam, friction, and an ultrasound are somenon-limiting examples of energy sources that may be used to weld a studto a part.

In these examples, the studs take the form of titanium studs. Thesestuds may be applied to other metals, such as steel, aluminum, titanium,or other metal alloys. Further, the studs also may be made of differenttypes of metals, depending on the particular embodiment.

With the use of studs, tabs may be attached to components with irregularcross-sections and/or complex shapes. Further, the attachment of tabswith studs may be performed off line from the machining area. This typeof process provides flexibility as to when and where tabs may beattached to parts.

Turning now to FIG. 8, a cross-sectional view of a stud attached to apart is depicted in accordance with an advantageous embodiment. In thisexample, stud 800 has been welded to part 802. The welding is performedusing capacitor discharge welding, in this example. This type of weldingprovides a minimal heat affected zone as compared to other types ofwelding processes.

Section 804 shows a fused area between stud 800 and surface 806 of part802. In this example, part 802 is a titanium part.

Turning now to FIG. 9, a more detailed cross-sectional view of aninterface between a stud and a part is depicted in accordance with anadvantageous embodiment. In this example, the heat affected area in thepart 802 is around 0.008 inches as can be seen in section 900. Section804 is an area where fusion has occurred between stud 800 and part 802.The metals in both of these components may have melted and fused in thisparticular portion. In the different advantageous embodiments, the partis machined or processed to remove this material. In these examples,about 0.2 inches of excess material is typically included on the partperiphery to ensure the heat affected zone is entirely machined away.Section 900 represents a heat affected zone to be machined away on thefinished part.

With reference now to FIG. 10, a diagram illustrating the placement of atab onto a part is depicted in accordance with an advantageousembodiment. In this example, studs 1000 and 1002 have been welded ontopart 1004. At this point, tab 1006 may be attached to studs 1000 and1002 by placing studs 1000 and 1002 into channels 1008 and 1010.Sections 1012 and 1014 are threaded sections for studs 1000 and 1002,respectively. These sections may be fastened to tab 1006 throughfasteners 1020 and 1022. Tab 1006 is now rigidly attached to part 1004.Devices 1016 and 1018 ensure that a mechanical lock exists between tab1006 to studs 1000 and 1002 when fasteners 1020 and 1022 are attached tostuds 1000 and 1002.

Depending on the implementation, devices 1016 and 1018 may be omittedwith fasteners 1020 and 1022 providing a feature for mechanical locking.As another non-limiting example, studs 1000 and 1002 also may take theform of a rivet, rather than having sections 1012 and 1014. Anymechanism for mechanically attaching studs 1000 and 1002 to tab 1006 maybe used.

In this example, tab 1006 also includes channel 1020. This channel maybe used with a fastener to fasten or affix tab 1006 to a manufacturingtool.

In this example, tab 1006 is attached to two studs, stud 1000 and stud1002. In other embodiments, other numbers of studs may be used. Forexample, a single stud may be used with respect to tab 1006. In otherembodiments, three studs may be used. Further, in these examples,devices 1018 and 1016 are shown as being fastened to sections 1012 and1014 on studs 1000 and 1002.

In other embodiments, a fastener, such as fasteners 1020 are 1022 areunnecessary, as in the case where studs 1000 and 1002 are integral(one-piece) with tab 1006. Another embodiment might include a singlestud with a threaded section may be placed into a channel in which thechannel has a threaded surface or interior to attach the tab to thestud. Of course, other fastening mechanisms also may be used in additionto these.

Turning now to FIG. 11, a diagram illustrating the holding of a part ona manufacturing tool is depicted in accordance with an advantageousembodiment. In this example, part 1004 is placed onto machine tool table1100, which is a part of a manufacturing tool. Tab 1006 is placed ontofastening block 1102 and bolt 1104 is placed through channel 1020 asshown in FIG. 10 to fasten tab 1006 to machine tool table 1100.

In this manner, the use for a larger block of material to create themachine tabs into part 1004 is unnecessary. As a result, less materialis needed to form part 1004, in these examples. With this type of tabassembly, tab 1006 may be manufactured using a different type ofmaterial as compared to stud 1000 and 1002 in FIG. 10. Further, tab 1006may be of a different type of material from part 1004. For example, tab1006 may be made of a different type of metal or alloy as compared topart 1004. In addition, tab 1006 may even be made of non-metalmaterials, such as, for example, a plastic or composite material,depending on the particular implementation.

Turning now to FIG. 12, a diagram illustrating a cross-section of a tabin a stud is depicted in accordance with an advantageous embodiment. Inthis example, tab 1200 includes channel 1202, which has differentdiameters or radii through tab 1200. Channel 1202 has a first diameterin section 1203, a second diameter in section 1204, and a third diameterin section 1206. In this example, sections 1203 and 1206 have the samediameter. Section 1203 and section 1206 have wider diameters thansection 1204, in these examples. Sections 1203 and 1206 in channel 1202are designed to allow the head of a fastener, such as a bolt, to beplaced completely within channel 1202 such that the head of the bolt orother fastener does not protrude or extend above surface 1208 or surface1210 when tab 1200 is fastened to a manufacturing tool or otherstructure.

In this example, tab 1200 also includes channel 1212 through which stud1214 may be inserted. In these particular examples, another fastener isunnecessary because channel 1212 is threaded to receive stud 1214.

As illustrated, tab 1200 is around 1.75 inches wide and around twoinches tall. Further, tab 1200 also includes section 1216. This is amachined section, which may be removed during processing of the part. Inother words, section 1216 may be machined away from tab 1200 during theprocessing of this part with a manufacturing tool.

Turning now to FIG. 13, a front view of a tab is depicted in accordancewith an advantageous embodiment. Channel 1212 with stud 1214 is visiblefrom this view of tab 1200. In this example, surface 1300 is around 1.5inches wide.

The different dimensions and configurations in these figures areprovided as an illustrative example of one advantageous embodiment andnot meant to limit the configuration or dimensions that may be used. Forexample, a tab may include two channels for fasteners. The channels alsodo not have to be round or circular. A portion of the channel or all ofthe channel could have a hexagonal or octagonal shape. Thus, thedifferent dimensions described and shown may vary, depending on theimplementation. Further, tabs of different sizes or dimensions may beattached to the same part.

Turning now to FIG. 14, a flowchart of a process for manufacturing apart is depicted in accordance with an advantageous embodiment. Theprocess begins by attaching a set of studs to a part (operation 1400).In these examples, the studs are rigidly attached to the part through awelding process. The set of tabs are one or more tabs, in theseexamples. The part may have been initially processed or formed throughprocesses, such as, for example, without limitation, extrusion,machining, and water jet cutting.

Next, a set of tabs are attached to the set of studs (operation 1402).The set of studs are one or more studs, in these examples. Depending onthe particular implementation, one tab may be attached to one stud. Inother examples, a tab may be attached to two or more studs. The tabs maybe attached to studs through a fastener or through threads located inthe channel in the tabs.

After the set of tabs have been attached to the studs, the set of tabsare affixed to a manufacturing tool (operation 1404). Thereafter, thepart is processed using the manufacturing tool (operation 1406). Thisprocessing may include, for example, drilling, machining, lathing, orpainting.

After the part has been processed, the tabs may be removed (operation1408). The tabs may be removed by applying a bending/shearing type forceto the tabs to cause the studs to snap off. The tabs, in these examples,are easier to remove because they are not formed as part of the part.Additional, the tab itself is not welded to or directly affixed to thepart. The studs have a smaller area, as compared to the tab, that isattached to the part. The studs may be undercut at the completion ofmachining or processing such that they may be more easily removed or“snapped” off by hand rather than if the tab itself was attached orwelded to the part. Current processes, in which tabs are formed on thepart, require machining or other processing to remove the tabs from thepart.

Thereafter, the part may be deburred to remove any rough surfaces on thepart left from the attachment of the stud (operation 1410). The processthen terminates.

Thus the different embodiments provide a method and apparatus forprocessing a part. In one advantageous embodiment, a setoff set of studsare welded to a part to form a set of fixed studs. A set of tabs areattached to the set of fixed studs. The set of tabs are affixed to amanufacturing tool.

As a result, some or all of the different advantageous embodimentsprovide for an ability to reduce the amount of material needed for apart. This reduction in the needed amount of material for a part occursin some of the advantageous embodiments because the amount of materialneeded for the part does not have to take into account machining orforming tabs as part of the part. Instead, the tabs may be attachedthrough the attachment of studs to the part. Tabs are then attached tothe studs to provide for a component to hold the part to a manufacturingtool for processing. Further, this type of configuration allows forflexibility in the location of tabs as well as a modular configurationof tabs. Further, different types of tabs may be attached to the samepart, depending on the type of holding mechanism needed.

The description of the present invention has been presented for purposesof illustration and description, and is not intended to be exhaustive orlimited to the invention in the form disclosed. Many modifications andvariations will be apparent to those of ordinary skill in the art.Further, different advantageous embodiments may provide differentadvantages as compared to other advantageous embodiments. The embodimentor embodiments selected are chosen and described in order to bestexplain the principles of the invention, the practical application, andto enable others of ordinary skill in the art to understand theinvention for various embodiments with various modifications as aresuited to the particular use contemplated.

1. A method for processing a part, the method comprising: rigidlyattaching a set of studs to the part to form a set of fixed studs;attaching a set of tabs to the set of fixed studs; and affixing the setof tabs to a manufacturing tool.
 2. The method of claim 1, wherein theattaching step comprises: welding the set of studs to the part using acapacitive discharge welding tool.
 3. The method of claim 1, wherein theset of studs are comprised of a same material as the part.
 4. The methodof claim 1, wherein the set of studs are comprised of a differentmaterial from the set of tabs.
 5. The method of claim 1, wherein the setof studs includes one stud for each tab.
 6. The method of claim 1,wherein each stud in the set of studs has a threaded section, each tabin the set of tabs has a channel configured to receive the threadedsection, the attaching step comprises: placing the threaded section intothe channel to attach each tab to the each stud.
 7. The method of claim1, wherein the each stud in the set of studs has a threaded section,each tab has a channel, the attaching step comprises: placing thethreaded section through the channel; attaching a fastener to thethreaded section, wherein the tab is attached to the stud.
 8. The methodof claim 1 further comprising: processing the part using themanufacturing tool.
 9. The method of claim 8, wherein the processingstep comprises at least one of drilling, machining, or painting thepart.
 10. The method of claim 1 further comprising: processing the partsuch that any heat affected zone resulting from rigidly attaching theset of studs to the part to form the set of fixed studs is removed priorto placing the part into service.
 11. A manufacturing system comprising:a plurality of studs; a welding unit capable of rigidly attaching theplurality of studs to a part; a plurality of tabs capable of beingattached to the plurality of studs, each tab in the plurality of tabshaving a channel to receive a portion of a stud in the plurality ofstuds and mechanically attach the stud to a tab; and a manufacturingtool capable of holding the part in place for processing using theplurality of tabs attached to the plurality of studs.
 12. Themanufacturing system of claim 11, wherein the manufacturing tool isselected from one of a lathe, a machine tool, a drill, and a paintingtool.
 13. The manufacturing system of claim 11, wherein the plurality ofstuds and the plurality of tabs are manufactured from a same material.14. The manufacturing system of claim 13, wherein the same material isselected from one of steel, aluminum, and titanium.
 15. Themanufacturing system of claim 11, wherein the plurality of studs ismanufactured from a first material and the plurality of tabs ismanufactured from a second material that is different from the firstmaterial.
 16. The manufacturing system of claim 15, wherein the firstmaterial is titanium and the second material is selected from one ofplastic, a composite material, steel, and aluminum.
 17. Themanufacturing system of claim 11, wherein the welding unit is acapacitive welding unit.
 18. The manufacturing system of claim 11,wherein the plurality of studs have a threaded section and the channelin the plurality of tabs has a threaded surface capable of receiving thethreaded section.
 19. The manufacturing system of claim 11 furthercomprising: a controller, wherein the controller controls a welding ofthe plurality of studs to the part.
 20. The manufacturing system ofclaim 11 further comprising: a placement unit capable of attaching theplurality of tabs to the plurality of studs.